Bristle tufting machine



Nov. 28, 1950 J. A. STARR 2,531,481

BRISTLE TUFTING MACHINE Filed Nov. 30, 1946 5 Sheets-Sheet 1 INVENTOR A7547 $7729? .ZzMwm ATTORNEY Now. 28, 1950 .1. A. STARR BRISTLE TUFTING MACHINE 5 Sheets-Sheet 2 INVENTOR \Zgfd v JEH/V ,4. $7,716?

ATTORNEY Nov. 28, 1950 J. A. STARR 2,531,481

BRISTLE 'I'UFTING momma Filed Nov. 50, 1946 s Sheets-Sheet s INVENTOR J'o/wv A. 5 THE/ 2 ATTO RN EY Nov. 28, 1950 J. A. STARR BRISTLETUFTING MACHINE 5 Sheets-Sheet 4 Filed Nov. 30, 1946 & a m 7 J mm 5 N5 R V 8/ w w m y 7/ 0 QM 5 e 5 g x 2 WW x 3 6 I 7 5 M M Z i TL: |I|.|I|| Inn-11 ME, WWII-1H: WHVIMILQ/ i w 4 7 a M 3 6 Nov. 28, 1950 J. A. STARR 2,531,481

BRISTLE TUFT-ING MACHINE Filed Nov. 30, 1946 5 Sheets-Sheet 5 I is 35 5 /0 I- 5 36 a Z a 2% g 9 is ii i:

v f2 58 I x 9- i5 J63 68 i 60 f I 6/ I 7 Q 5 63 58 I 59 9 48 3\ 48 f 52 I 62 46 I 47 I OH 2 li 1 x 5 8 I a x 5/ 7 39 3s as,

i I 1 2 T 40 y 40 INVENTOR ZfiY a Mun -"butt ends of the bristles tused together.

Patented Nov. 28, 1950 UNITED STATES PATENT OFFlCE BRISTL'E TUFTING .MACHINE John A. Starr, Riverdale, N. K, assignor to M. W. Jenkins Sons, Inc.;.Qedar Groye, J.., a corporatiomof New Jersey PDlicatiomNovcmber 30, 1946, ;SerialNo.'713,341

This invention relates to a bris-tle *tufting :ma-

chine which automatically *combines -together a multiplicity of plastic bristles into tufts with :the The bristles maybe made from any suitable plastic which is solid and hard at temperatures under 250 F. lout which will :soften and -liquifywhen suflicient heat is applied-thereto, and :will again harden or solidify when cooled. The tufts thus formed are particularly-adapted for use in'mak- 1 ingtufted brushes. Thetufts after leaving the 'ttiftin-g machine are secured in holders to form brushes. The :"secur-ing of the tu'ftsinthe holders may be done either'manual-ly :or automatically,

depending on thetype' of brush being made.

The principal objectof the invention is to provide a *bris'tle tufting machinewhich'will automatica-lly combine a multiplicity of plastic bris- *tles intotufts with their bu'tt ends all fused together.

Another object of the invention is to provide a machine of this character which is of simple construction and very efilcient inoperation.

Another object of "the invention is to provide a --machine of this characterwhich can be quickly sume after a predetermined length of. .a rope-of :plasticbristle strands has ibeen fed forwa-rdlyi to "bring the end thereof into contact with asuitable heater;

Fig. 2 is a top-plan sview raof .athe machine :shown iinlFl'g. 51:;

. sFig. 3.11s a ,horizontal'rsection, through the maiQhinefiitiZkeHOn the aline ;3'-;3 :cf Fig. i just above :the shearing mechanism and .showing the zshears :in :theirzclosed :position iorithe :POSitiOIl 1theyassome justhaiterhaving- :cut :3; predetermined length irom-the rope:ofibristle strands;

v;;Fig.4iis 1a viewzsimi'lar :towEig. B shoWJingthe shears fin their open position'z ready for another predetermined length-of roperto be fed ithereby;

Fig.5, is ta "horizontal section taken on'the line .55 ofIFig. .1 just above the clamping jaws which clamp :and :hold the .end :cf. the :rope in contact with the ;heater-;while the rope feedingimecha- .nismiis retracting r preparatory "to advanoingranotherepredeterminedzlength .ofsrope;

.91Glaims. (Cl; KGB-+29 Rig. 6 is a view similar to Fig. :5 ,showingthe clamping jaws in their open-position;

*Fig. 7 is a horizontal section taken on the line l-J of Fig. 1 showing the operating arm for, the rope feeding mechanism in' mid position;

' '--*Fig. 8- is a fragmentary section takenon the line -88 of Fig. 7;

Fig. 9-is a vertical section-taken on :the ..-1ine 9-9 ofFig. 1-,showing the relation of the various operating cams to each other;

Fig: 10. is a-vertical section taken on theline 'I0l-1) of Fig. :1 showing the relation of the rop teeding mechanism,'the shearing mechanism and the I clam-ping j aws to eachother; Fig: 11 1s a fragmentary sectional :side elemt'ionofsthe forward end of the machine showing the rope feeding mechanism in :its lowermost position or the :position it assumes afterhaving fed forwardly a pr t mined length ofrone; "Fig. 12 isadevelopment-ofithetdnumnam which operates .the :rope feedingmec'hanism in timed "relation to the rest of the-machine;

i Fig. 1 3 isadetail plan viewof one of itheclam-ping' j aw -operatingcams'; and

*F'ig. 14 is a perspective view of .one of the tufts tormed by -the machine.

This machine is designed to form bristle :tuits trom'a long rope of brist1e strands. .'.The bristle Jsivelyfeeds predetermined lengths thereof: past a --sheari-ng mechanism and a pair :of :clamping jaws and successively brings the endof the rope into contact with. a suitable heating mechanism. Just as the end of the rope contactsithe "heating -mechanism the clamping -j aws .elose and tightly grip:andfi-hold the rope near the end thereofas shown in Figsi :5 andl'l. The :jaws hold the end ot the rope in -'contact with' the :heatingmechaman -while the rope feeding mechanism :moves from the position :shown in Fig. 111 back toits 'z-initialyposition as shown in Fig. 1. After :the feeding mechanism reaches its initial-position it";dwells for aninterval before again-moving idownwardly fito 'feed'rthe next length of rope. *Durging tliisa dwellwof the feeding mechanism the "shearing mechanism :is operated, cutting oiT' :the length :of rope therebelow. "The clampin iaws thenopenreleasing the rope and the cut-off piece is then removed hom the machine. This -can be :done tmanually :or if desired suitable mechanism -::may betprovidedto automaticallyremove the cutoff ends of the rope. The heat applied to the ends of the rope of bristle strands melts it and causes the ends of the bristles to all fuse together. Then as the cut-off piece is removed from contact with the heater the melted portion quickly sets and hardens into a single solid sheet with the bristles extending upwardly therefrom.

Referringnow to the drawings by reference characters, the numeral indicates generally a frame which supports the various mechanisms which make up the machine. The frame I consists of a base 2 and an upwardly extendin web 3 which is secured thereto. The Web 3 has an upwardly extending open ended cut-out position 4 near the rear end thereof and an open ended forwardly extending cut-out portion 5 in the forward end thereof. A flange 6 formed integrally with the web 3 extends outwardly from each side thereof around the cut-out 4. The upper end of the cut-out 4 is closed by a cap 1 which is secured -in place by bolts 8. The forward end of the web 3 above the cut-out 5 terminates in an enlarged section 9 having a vertically extending open ended cylindrical bore l therein.

A vertical cam shaft II by which all of the various mechanisms of the apparatus are operated in timed relation to each other is rotatably supported, by bearings l2 and 13, within the cutout 4. The cam shaft I i has a bevel gear i4, rigidly secured thereto, which meshes with a bevel gear l secured to the forward end of horizontal shaft i6 rotatably supported in a bearing H. A spur gear 18 which is secured to the rear end of the shaft 16 meshes with a spur gear l9 secured to a shaft 20 extending out from a gearcase 2|. The cam shaft H is constantly driven at the proper speed from the shaft 20 through the gears l9 and i8, shaft I6 and bevel gears l5 and I4.

A feed slide 22, having a, reduced cylindrical extension 23 which extends out through a plug 24 in the lower end of the bore I0, is slidably mounted in the bore Ill. The slide 22 has an axial bore 25 in which is secured a liner 26 of suitable "wear resistant material such as chromenickel steel. A stud 21 which is carried by the slide 22 extends out through avertically extending elongated slot 28, in'one side of the enlarged section 9, and has mounted on the outer end thereof a roller 29. The roller 29 is engaged by the bifurcated end 30 of a lever 3 I which is pivotally supported by a stud 32. The other end of the lever 3| has a stud 33 secured thereto which carries a roller 34 which is adapted to ride in the cam track 35 in a drum cam 36 secured to the upper end of the cam shaft l I. As the cam shaft .H and cam 36 rotate, the lever 3| will be oscillated on the pivot stud 32, making one complete oscillation for each rotation of the cam 36. The lever 3| will in turn reciprocate the feed slide 22. The cam track 35 is so shaped that th slide 22 will dwell at the upper and lower limits of its movement as will be explained in detail hereinafter in connection with the description of the operation of the shearing andthe clamping mechanisms.

A metallic heating disc 3! having a cup shaped recess 36 therein is disposed in axial alignment with the feed slide 22. The disc 37 is supported and heated by a suitable electric heating unit 39 which rests on a heat insulating strip 40.

A rope 4! made up of a multiplicity of long plastic bristle strands is threaded through the liner 26 until the end of the rope extends out of .the lower end of the liner a short distance. The

rope 4! is frictionally engaged by the liner 28 with sufficient force to feed the rope if no appreciable resistance or drag is applied to the rope. But if the rope is held the liner 26 will slide along it as the feed mechanism moves. After the rope has been properly inserted in the feed mechanism with the end thereof extending out of the lower endof the feed mechanism a short distance the machine is started in operation. The feed mechanism then moves downwardly from the position shown in Fig. 1 to the position shown in Fig. 11, carrying the rope with it until the projecting end enters the cup shaped recess 38 with the ends of the strands in contact with the heating disc 31. Just as the feed mechanism reaches the lower limit of its movement the jaws of a clamping mechanism generally indicated by the numeral 42 are brought together and firmly clamp or grip the end of the rope between them just above the heating disc 31. At the lower limit of its movement the feed mechanism dwells while the clamping. jaws are being brought together to rip the rope. As soon as the clamping jaws have gripped the rope, the feed mechanism quickly moves back to its initial position, sliding up about the rope 41 which is held from movement by the clamping mechanism 42. The feed mechanism then dwells at the upper end 0f its movement for an appreciable period. During this dwell a shearing mechanism generally indicated by the numeral 43 is operated to cut off the end of the rope therebelow. Both the clamping mechanism and the shearing mechanism are then opened and the cut-off end of the rope, now forming a tuft of bristles 44, is removed from the machine. During the time the end of the rope was held in contact with the heating disc 3! the ends of the bristle strands melted and fused together. As the tuft 44 is removed from themachine the melted lower end thereof quickly cools and solidifies into a thin sheet, as indicated at 45 in Fig. 14, with the bristles extending outwardly therefrom. It will thus be seen that a tuft of bristles having the butt ends of the bristles all fused together is formed during each cycle of operation of the machine. g

The clamping mechanism shown in detail in Figs.'5, 6 and 13 comprises a pair of opposed levers 46 and 41 which are pivotally mounted upon a supporting shaft 48 intermediate their ends. The shaft 48 is supported in suitable sockets 49 and 50in the web 3 and extends across the cut-out portion 5 of the web. The forward ends of the levers 46 and 41, which constitute the clamping jaws, each has an opposed semicircular recess 5| in the edge thereof. The radius of each of these recesses 5| is substan tially the same as the radius of the rope being used' and when the jaws are closed as shown. in Fig. 6 the center of these recesses is coincident with-the axis of. the feed slide 22. The levers 46 and 41 are mounted one above the other upon the shaft 48 as shown in Figs. 1, 10 and 11. In order to bring the forward ends of these levers into register with each other the lever 41 is bent downwardly the thickness of the lever 46 as indicated at 52. The rear'end of each of the levers 46 and 41 is recessed, as indicated at '53, and has a roller 54 mounted therein upon a stud 55 extending across the recess 53. The rollers 55 are engaged by cams 56 upon the cam shaft II. The cams 56, which are identical with each other, are disposed one above the other in opposite phase upon the cam shaft H. The upper cam 56 operates the lever 41 and the lower cam 56 screws 68.

' operates the lever lt. These icams'whichrare shown in detail in'Fig. 13 are :so. shaped that iiaws will be held closed, as shown :in Fig.5, during the-first 150 rotation :of the will open during the next '60 rotation 20f the cam "shaft 11,- will be held open duringf the next 90 rotation of the cam shaft and will close during the next" 60 rotation oflthe :camshaft. Suitable spring-means '5! is' provided to open the clamping jaws.

The shearing mechanism fl comprises :a pair of identical opposed levers 58 which are mounted one "above the other upon the shaft 48 between collars '59 which are held in position upon the shaft &8 by set screws '66. Each lever 51-.hasa

"shear blade 61, having a-semi-circularcutting edge 62, secured to the forwardend thereof.

The rear end of each of thelevers 58' is bifurcated, as indicated at 53, and has aroller 63 mounted therein upon a stud :65. The "rollers 54 are adapted to be engaged :bycams 66 dis- :posed-one above the other in opposite phase upon "the cam shaft H between collars 67 which are held in position upon the cam shaft I I by set The cams t6 areso shaped that they will operate the levers as to move the cutting edges -52 of the shear blades fi l from the position shown inF-ig. '4 to the position shown in Fig. '3 to-cut the rope during 73 rotation of the cam shaft I l,'wi1l 1et the shear blad'es move back to open position under the influence of suitable spring means 68 during the next 73 rotation of the cam shaft ii, and will allow the levers and shear blades to dwell inthe position shown in .Fig. 4 during the next 214 rotation of the cam shaft II. It is during this 214 dwell that the feed slide 22 moves from the position shown in Fig. 1 down to the position shown in Fig. 11 and back to the position shown-in Fig. 1.

A development of the drum cam 36 which 013- era'tes the .feed slide 22 through the lever 3| is :shown in .liig. 12. From this "view it will be seen that the cam track 35 comprises upper and lower straight sections it and M respectively which are connected by inclined sections 12 and T3. The lower section ll extends 146 around the cam 36 and the upper section 19 extends 64 around the cam 35 diametrically opposite the section H. The sections 12 and 13 each extend 75 around the cam 35. From Figs. 1 and 12 it will be seen that the section H will cause the feed slide 22 to dwell at the upper limit of its movement during 146 rotation of the cam shaft M; and that the section ill will cause the feed slide to dwell at the lower limit of its movement during 64 rotation of the cam shaft II. It will also be apparent that the slide 22 is moved downwardly, after dwelling at the upper limit of its movement, during 75 rotation of the cam shaft II; and that after dwelling at the lower limit of its movement it is moved upwardly during the next 75 rotation of the cam shaft II.

In order to adjust the apparatus for making tufts of dfferent lengths, provision is made for varying the stroke of the feed plunger 22 and the position of the shearing mechanism 43. The lower limit of the slide movement must be the same for all length tufts as no provision is made for varying the position of the heating element 39 and heating disc 31 with which the end of the rope M is brought into contact each stroke of the feed slide. lhe adjustment is made by changing the upper limit of the slide movement, and this is accomplished by changing the position of pivot stud 32 both with respect to the as desired.

frame 1 and the lever :31. Changing the -position oft-he stud '32 with respect to thellever 13:1 increases or decreases the stroke of the slide22, and by changing its position with respect tothe framethe lower limit of the slide movement ismaintained the same regardless of the length of the stroke.

In order .to make this adjustment to enable the apparatus to form tufts of different lengths the pivot stud 32 is adjustably mounted in 3111131011! :ga'ted *slot BEl through a thickened portion 81 of theweb 3. This slot slopes downwardly to-the right as shownin" Figs. 1 and 11. The lever 3:] an elongated .slot :82 therethrough in which is slidably mounteda block 83 havinga bore 84 for the reception of'the stud 32 (see Figs. '7 and '8). The stud 32 also extends-through a spacing collar 85which maintains the lever B! in proper position with respect to the cam 36 and feed :slide'22; The block 83 is adjusted and maintained in position in the slot 32 by a screw86 which is mounted in a threaded aperture 8'! in a boss, adjacent one end of the slot 82, and hasone :end thereof rotatably mounted in a T-slot 89 "the block 83. "The boss 88 is slotted as shown at 59 and a bolt 9! is provided for clampingthe screw 85 in adjusted positions.

The position of the shearing mechanism is ad-.

justed by loosening the set screws :60 and'raising :or lowering the levers 58 uponthe pivot shaft 48 in accordance withthe adjustment of the feed slide 22. The position of the cams 66 upon "the camshaft i must also be changed in accordance with-any ehangein position of the 1evers'58. This is accomplished by loosening the set screws .68 and moving the cam up or down onthe shaft H In the drawings the apparatus is shown as adjusted for making the maximum length tufts within the capacity of the' machine.

From the foregoing it'will be apparentto those "skilled in this art'that I have provided a' simple and e'fhcient mechanism for accomplishing {the objects of the invention. It is to be understood that'I am not limited to the specific construction shown and described herein as various modifica tions maybe made thereto within the scope "of the appended claims.

I claim:

1. In a device of the character described the combination Of a heating element, a reciprocable slide operative to successively advance the end of a rope of plastic bristle strands into contact with said heating element, means for clamping and holding said rope while said slide is returning to its initial position, means for successively cutting the advanced length from said rope, and means for operating said reciprocable slide, said gripping and holding means and said cutting means in timed relation to each other.

2. In a device of the character described the combination of a reciprocable slide operative to successively advance predetermined lengths of a rope of plastic bristle strands, means for applying sufficient heat to the advanced end of said rope to fuse the ends of the bristles together, means for reciprocating said slide, and means for varying the length of the stroke of said slide.

3. In a device of the character described the combination of a heating element, a reciprocable slide perative to successively advance predetermined lengths of a rope of plastic bristle strands into engagement with said heating element, means for gripping and holding the end of said rope in contact with said heating element while said reciprocable slide is returning to its initial 7 position, means for successively cutting said advanced lengths from said rope, a cam shaft having a plurality of cams secured thereon, operative connections between said cams and said reciprocable slide, said gripping and holding means and said cutting means through which said reciprocable slide, said gripping and holding means and said cutting means are operated in timed relation to each other, and means for rotating said cam shaft.

4. In a device of the character described the combination of a heating element for applying heat to the end of a rope of plastic bristle strands to fuse the ends of the strands together, a reciprocable slide operative to advance the end of said rope into engagement with said heating element, and means for reciprocating said slide and causing a dwell in its movement at each end of its stroke.

5. In a device of the character described the combination of a heating element for applying heat to the end of a rope of plastic bristle strands to fuse the ends of the strands together, a reciprocable slide operative to advance the end of said rope into engagement with said heating element, means for reciprocating said slide and causing a dwell in its movement at each end of its stroke, and means for varying the length of the stroke of said slide.

6. In a device of the character described the combination of a heating element, a reciprocable slide operative to successively advance predetermined lengths of a rope of plastic bristle strands into engagement with said heating element,

means for gripping and holding the end of said rope in contact with said heating element while said reciprocable slide is returning to its initial position, means for successively cutting said advanced lengths from said rope, a cam shaft having a plurality of cams secured thereon, operative connections between said cams and said reciprocable slide, said gripping and holding means and said cutting means through which said reciprocable slide, said gripping and holding means and said cutting means are operated in timed relation to each other, means for rotating said cam shaft, and means for varying the length of the stroke of said slide.

7. In a device of the character described-the combination of a heating element for applying heat to the end of a rope of plastic bristle strands to fuse the ends of the strands together, a reciprocable slide operative to advance the end of said rope into engagement with said heating element, means for cutting sections from said rope after each advance of said rope by said slide, means for varying the length of the stroke of said slide, and means for adjusting the position of said cutting means.

8. In a device of the character described the combination of a heating element for applying heat to the end of a rope of plastic bristle strands to fuse the ends of the strands together, rope advancing means operative to successively advance the end of said rope into engagement with said heating element, and means for operating said rope advancing means and causing a dwell in its movement at the end of each advancement.

9. In a device of the character described the combination of a heating element for applying heat to the end of a rope of plastic bristle strands to fuse the ends of the strands together, rope advancing means operative to successively advance the end of said rope into engagement with said heating element, means for operating said rope advancing means and causing a dwell in its movement at the end of each advancement, and means for varying the distance the end of said rope is advanced by said rope advancing means.

JOHN A. STARR.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES- PATENTS 

